Method for forming metal powder into a fluid guiding body



Sept. 29, 1953 R. P. SEELIG 2,653,377

METHOD FOR FORMING METAL POWDER INTO A FLUID GUIDING BODY Filed Seph. 2, 1947 7 Sheets-Sheet 1 r--|.--- 4|- 1 46 v @h'fij. 48 47 k? 4T A H: I 49 4 L- I a/a T ,P/cHA 120 R 5554 /6 BY A TTOENEY Sept. 29, 1953 R. P. SEELIG 2,653,377

METHOD FOR FORMING METAL POWDER INTO A FLUID GUIDING BODY Filed Sept. 2, 1947 7 Sheets-Sheet 2 uvmvrok PIC/MRO 0. 6551/6 A TTOQNE Y R. P. SEELIG Sept. 29, 1953 METHOD FOR FORMING METAL POWDER INTO A FLUID GUIDING BODY 7 Sheets-Sheet 3 Filed Sept. 2, 1947 INVENTOR. /cHA 120 P. 5551. I6

A TTOENE) I Sept. 29, 1953 R. P. SEELIG METHOD FOR FORMING METAL POWDER INTO A FLUID GUIDING BODY Filed Sept. 2, 1947 k 2A 31 1'2 30 29 z '7 Sheets-Sheet 4 & INVENTOR.

Mal/1R0 2 55H /6 P 1953 R. P. SEELIG 2,653,377

METHOD FOR FORMING METAL POWDER INTO A FLUID GUIDING BODY Filed Sept. 2, 1947 7 Sheets-Sheet 5 74 5 72 3 71 7'5 .0 75 75 7s Magi-J3. 78

go I 80 RICHARD P. SEEL/G A TTOP E'Y Sept. 29, 1953 R. P. SEELIG 2,653,377

METHOD FOR FORMING METAL POWDER INTO A FLUID GUIDING BODY 7 Sheets-Sheet 6 Filed Sept. 2, 194'? A 7' TOP V5 Y Se t. 29, 1953 R. EEEEEE 1e 2,653,377

METHOD FO IDING BODY Mali ,e/cHA e0 2 SElL/G 10 ZflUZAM 11 A 7'TOENEY Patented Sept. 29, 1953 METHOD; FOR FORMING METAL POWDER); INTOAFLUID GUIDING-BODY Richard P. Se'elig; Ehnhurst, 'NrYigLassignor to American Electro Metal Corporatiom'Yonkersp NLYJ; a corporation of Delaware Application September 2, 194:7; Senial No. 'Z'ILBS'Z.

4 Claims.-

This invention relates. to the manufacture .of. I bladesor. vanes and similar parts of turbines, particularly gas turbines and compressors, which. are-difficultto manufacture by casting and forging methods especially because of the .finishing, operations subsequently required. Such apart usually consists. of a blade proper and a root for securingit to a support. The bladeis curved and twisted and notpf simple geometric shape It'is an object. of the invention to produce such parts in a powde'rmetallurgical process, from the powdersof metal of which the blade orvane is to consist;

I t-is a "further object of.theinvention to pro-. ducesuch parts in' .a combined powder metal-' lurgicaland infiltrationiprocess in which one or more kinds of metal-powder are pressedcto desired porous-shapeand afterwardsinfiltrated by another kind of metalior' metals .of lower melting... poin't'than that of the firstmentioned kind.

It-is another objectof the invention to render more simple'and inexpensive the manufacture of. parts of complicated :or intricate shape; such "as blades and buckets;

It is a still furthenobject of the invention.to manufacture, in simple and inexpensive mass. production, "bladesand similar shapes of rather... complicated and intricate configurationso that the final articles" are Within. close tolerances.

These and other objects; of the invention willll be more clearly understood as the specification proceeds with -referenc e" :to the drawings; in... whicl-ifby- 'way or 'exemplificatioh Fig. 1 '.'shows' a verti'cal cross-section-with partsin elevation of -"es'sentia'l elementsot an 'open pressifo'r Qprlee. shaping 'a blade from metar'pmvder, '-.Fi'g; 2 'a bottom'-'viewof the upperpunchassembly fand adapten parts along -line22 in Fig: LiF'igX 3 "3. plan view of the die -andidie adapter ralong the... line 3- -3 in -1 ig.' 1, F'ig.; l a *cr'osssectidn-pf the punch and die -assembly "along line; i e! in; Fig-w 1,=Figs: 5,- 7, 931i "vertical cross' sectional" views on a --larger sca'lefitakeniirr'the same-plane; as--Fi'gT.- -1, of the upper and -lower punchandjdie assemblies 'difierenb compressionalJpositidns, and Figs-$6, 8, wand 12- vertical cross" sectional views along-linest fi, =8- 8,"? I 0*:I H," I 2j--I respectiv'ely'fin-Figs:* 5,"7, 9 and 11-,-Figs. 9wand-9li vertical sectional views of modifications ofthe' str uctureshown in Fig: 9; Fig: 13 a "viewssimilar to Fig-) 1 pi an open;- dieio'r; finally" shaping the preshaped--' blade; '--Fi'g*;--14 "a bottom "-yi'ew'along j line I 4-I i or the "upper-die and punch assembly shown in Fi'g.--l3,'-Fig';-l5 a plan-view'oi the lower die and ilie -adapteralong line I5'*"I 5- in'Fig:;i13;;. Figshlfi; 18 and 20; -on -a -la'rger-*scaleisuccessiveccmpressiehal "positions of" the-. die's j in the. shapin eoperation 'and figs. 1'7, 19" and 21 re spectively, vertical cross sectional views-along li1'1es..- I'I:,-I 'I,'.I9-?I9 .anfl '2I"-2I" in'zFigs;-*167,l8 and 2Q,Irespectively,,Fig v22 ona still larger scale along line. 22- -22; in Fig. 19gthe finalishapingtdieshimclosed position with ;an-*interposed blade seenendwise, and Fig. 23 a side'view of the finallyshaped blade.

Referring to Fi'gc23fir'st, the blade is isfprovid'ed with'a root II for insertion in a g'rooveror the like of. a supportingwheel or disc or' a sta tionary difiusor; The. blade tapers" over-a part of itsile'ngthfromthe .root; itsthickness-variesover its cross section similar to that of an air 011.. There is also a longitudinal" twist of-thebla'de; as appears from Fig.;23;

To manufacture such complicated shapes-isobviously. difiicult and expensive; because-oftlie considerable twist and highlycurved-surfaces of the blade, it is. also impossibleto press it "irra singlestep from a metal-powder? Therefore, a preshape ismolded from the meta-rpowder and is finally shaped inat least one subsequent step.

If blades are, concerned which are produced in a combined" powder metallurgicar and infil tration process, a porous compactor preshapeismold'ed first and thereafter infiltrated withfa metal of lower melting point-thanthat of-=the-- porous shape. For the porous shape,- ferrous metaldpowder is preferred and in particular pure reduced iron to which carbon "in amounts up to about 0.25 to. 0.4 %:"may.beadded in-solid form;- such .as of finely divided graphite. This initialpowder'is filled into the preshaping or molding die.

Referring .to. 'Figs.;:1 and-'4, the lower portion ofv the punch'and die assembly includes a bolsterplate I5 in which a plurality'of stripperybolts IB' "are mounted which pass slidingly throughholes in the die holder IT. The-stripper bolts are provided withstop nuts I8 to limit-the up-- ward-movement and define the upper positionof the 'dieholder -Il. Springs I9 surrounding the .stripperbolts I 6 hold the die holder I 1 yield-" ingly in. its upper-position. Guide posts-20 mounted-on the bolster plate-IS-pass slidingly-s through-bushings-2I andin holes in the-die holder I'I.

The die'retainer 22 is'secured against a shoulder in the die holder I'I bymeans of a ringnut The'die 24 is inserted into its retainer'22 and held bya ring nut 251* The die cavity comprises a 'portion 26--to-formthe root andanother por tion '21 to formthe blade proper 0f 'a'turbine blade. In the portion ZS of-the die-cavity, a a punch 28 is movably-arrangedywhereas inthe portion 2 'i-j 'three complementary punches 29, 30 and 3| are movably arrangedfi The-=punch:-28"

extends through the punch holder 32 and is rigidly mounted on the punch holder 37. Punches 29 and 3! are mounted on a punch plate 32 and thereby moved in unison whereas punch 3e passes through punch plate 32 and is mounted on another punch plate 33, the two plates being yieldingly mounted on sets of springs 34 and 35 respectively. The springs 34 are supported by a punch stop 36, and the springs 35 are mounted on the punch stop 31. The uppermost position of punch plate 3 2 is defined by guides 38 mounted on punch stop 3'5 and having stop nuts 39. The upper position of punch plate 33 is similarly defined by guides 49 and stop nuts 4|. Punch stop 36 is mounted on the bolster plate l5, whereas the downward projection lll of punch stop 31 engages an adjustment nut 52 which rests on the bolster plate 5.

The upper punch assembly includes a punch 43 to fit in die cavity portion Ti, and another punch it to fit in die cavity portion 26. Punch 43 is mounted in a punch plate 45 which is spaced from punch holder :35 by means of pressure springs l! and guide pins B8. Cap 69 defines the lowermost position of punch plate 55 with respect to the punch holder 46. Punch 44 is rigidly mounted on punch holder 43.

The complementary punches 29, 3E] and 3! are shown in Fig. 1 in their initial positions to provide a sufficient column of powder (powder fill portion) [69 above each punch so that upon compression the respective columns or portions of the fill are compressed in the desired compression ratios.

Similarly, punch 28 is positioned so that the measured fill portion above it, upon compression, will form the root at the desired compression ratio.

The powder is filled into the die cavity portions 28 and 2'5 flush with the top surface of the die. Thereby the amount of metal powder filled in the die is predetermined within close tolerances.

Upon lowering the upper punch assembly, punch 43 contacts the upper surface of the powder fill i853 (Figs. 5, 6).

Upon further continued motion of the upper punch assembly, punch 43 enters portion 21 of the die cavity and compresses the powder therein; the compression force translated through the powder moves the lower punches 29, 3t and 3f downwardly against the pressure of spring 34 and 35. Since the fill portions above punches 2s, 3| are of less depth than that of the fill portion above punch 35, Fig. 5, punches 2e, 3i will travel downwardly a greater distance than punch 3t in order that the pressure surfaces of these punches be brought into register by the time the powder fill has been compressed. Punch 44 enters the die cavity portion 26 after punch 53 has moved downwardly in the portion 27 of the die cavity to some extent, and compresses the portion of the fill in the cavity portion 26.

Shortly after compression started, punch 43 retracted against the pressure of springs 4'! in its uppermost position relative to the punch plate support 48.

Punches 29, SI yield to a greater extent than does punch 36, and intermediate relative positions of the three punches are shown in Figs. 7, 3 with the upper root punch 14 having entered to some extent into the cavity portion 25. It will be observed that the cooperating root punches M and 28 are rigidly mounted on the respective punch holders 45 and 41.

Upon full compression as shown in Figs. 9, 10, the pressing surfaces of the complementary punches 2Q, 38, 3% are in register; the blade portion like has been compressed and formed with flat edge faces and the root portion between the punches 44 and 28 has likewise been compressed to form the desired porous preshape. During compression, the die plate ll was moved downwardly slightly against the action of the pressure springs l9 by virtue of the friction between the powder fill and the confining surfaces of the die.

In this exemplification of the invention, the pressing surface of punch 43 is shown flat. Instead, this pressing surface may be urved laterally as indicated by line 53 in 9a.

In order to avoid sharp corners on the preshape and to approximate more closely the shape of the edges of the final shape, sharp projections or chami'ers 5i, 2, can be provided on the sides of punch 3 as shown in Fig. 9b; the surface between the chamfers is preferably curved as is also shown in 9b, to approxtmate the final shape.

The thus compacted porous preshape is ejected by lifting the punches 2S, 3! simultaneously. To this effect, an ejector rod 5d, igs. 1, 4, attached to the downward projec on M of the punch support 3? moves the latter upwardly, whereby punch 39 and the root punch 23 are lifted in unison and lift the preshape. This lifting and ejection of the preshape is permitted by simultaneous retraction of the punch holder 9 with the root punch :24, punch piate 45 and punch 43. The retraction of the punch holder 46 may permit some expansion of the springs l! but is preferably so regulated as to maintain sumcient pressure by the punch is on the preshape to prevent injury to the edge portions of the preshape from friction with the side walls of the die 24. The ejection continues until the preshape Hi! is lifted above the top surface of the die 24 as shown in Fig. 11, whereupon the upper punches 43, 44 are fully retracted so that the preshape is cleared and can be removed. Thereafter, all the punches are returned to their initial positions as shown in Figs. 1, 4 and another cycle of compaction can be started.

The preshape or compact is now sintered and the sintered compact is to be given its final shape.

For this purpose, the die assembly shown in Figs. 13, 14, 15 is used. It includes a die retainer 55 slideably arranged on stripper bolts 56 which are mounted in a bolster plate 51. Pressure springs 58 tend to move the retainer plate 55 against stop nuts 59 on bolts 56. A lower die 60 is mounted in retainer plate 55 by means of a ring 61 secured thereto by means of screws 62. A punch 63 for finally shaping the root is secured to punch plate 64 which rests on bolster plate 51 and is guided within a lower stop 65 for the lower die 68. Root punch 63 is movable within a slot 61 in die 50. Die 60 is provided with a pressure surface 66 corresponding to the final shape of the lower surface of the blade proper.

The upper die and punch assembly comprises the die 68 provided with a pressure surface 69 which corresponds to the final shape of the upper surface of the blade proper. The upper die is further provided with a slot 10 in which the upper root punch H is movable. The latter is rigidly mounted on the die support 72. Pins 73 are mounted in die 68 and passed through holes 14 in die support 12, These pins have heads to finallshape becomesstuckiinthe uppendie' cavity '10 B9 'or slot 10, upon'rremoval of the :stops, they die can' be moved further upwardly. relativeuto. support 12 and the root punch H can ej'ectxthe: bladefromthe die cavitynr slot! Upon: insertioneof: athe :preshape :between ethe -15 dieswvith' itlre; :rootr in'zthez slot.- or; cavity 615, and, upon lowering. ofithezupper diez-and punch: asseme; bly,"ithe1;dies. makatcontact inzthev manner-:asz shown inFigs16,:17.z.

float .:respectively downwardlyiiand upwardlyninr relation :tow their: holders; stovercomingizthei ipresi-a sures of; the "springs::58,r 1 5 respectively: so: that; ringefi I: hitszhomenzonastopz 65,-: diexsupportal Zrhits: home on: stops :1 punches- .63 and: 1 I :come. rintoncontactnwith Tthi: 1 adjajcentrsurfaces 'ofinthenrootial I145 tot zthe'ipre-i shapeas shown in-Figsa 18; and-192:1;

In.icomp-ressing the blade;;.part;- of the material:

of rtha bladez is displacedclaterally. in ;a swaging v2.

action-sand ialsozzthe predetermined twist-.isxim-r. parted stop it: Thus1a :shapingqandtwisting ;.and 7. not; merelylza isizinghoperatiom isi-performed:

The :cavity 'between ethez'finali die-surfaces -56;

and 363,-: shown Pigg 13, is: slightly (wider ithan1 the die cavity pin) the: zpreliminaryvdiewfl; shown; in Fig; 1,; ini orderrthatz. gthe'stmetal. under. the :1-. pressure of J the; final. dies-:may: *be forced laterally toward the side edges of thelnavitymhus widene ing, shaping and increasing; the :density" of, the! shown in Figr13. The parts of "the lower die and punch assembly return also to their initial positiizn-i-sr Now the-ejector piri'sfiG-lift thepun-ch plate: filiiiandtherebyroot =63 relative-to die-60, whereby the final-ly-shapedblade is lifted above thetlower"die'surface intowgth'e positionlas ing range of thefipreshapes'so. that the latterris shown .in Fig.1 20 A and is-now free and can be removed-fromthepress v Ifiit is difficult. in .a single-finalshaping operation as describedto obtain spanner shape" ofthe blade; suchias in.caseslofnextreme-twistssofthe ated by lateral displacementrofgmaterialitoward 755 6 the; edges 20f rtheeblade .andscby -densifyingeitss porousistructu're; and. in the third .step' thertwist s;- is :impartedrto the :blade and a final'lsizinglgivena t0:it.;

After. theiporous .preshape. has been. compacted',isintered;" further asized under pressure and infilt'rated;it is often advantageous to apply finalz sizing: and twisting4pressure to the surfaces ofthe infiltrated preshape.

Abladei orbuclretiean :be shapedin the process hereinbefore :ldeseribed from highly refractory metal; such as :rnolybdenu'm, tungsten or an al-" loyof-bot-h... Thefinally shaped,' and if required; sized loomed-) :blade or bucket is usually denser If; in; the production of blades or buckets of larger size from molybdenum or tungsten, a presintering :step hasbeen interposed between: the two shaping steps; the final shape may not yet besde'nse enough to 'exhibit.greatest rigidity and strength. In such"oase; the final shape can-be subjected-to a=high sinteririg treatment to fully' 4 densify zit and a sizing (coining) step applied only tothe high 'sintered shape, if requiredf A corrosion resistant coating, such as of chro ;13 whereby, t e 1 525" 'mium, I titanium; aluminum and chromium 'borides is applied thereafter; The titanium" or aluminumis oxidized thereafter toform a dense corrosion-resistant coating @on its outside. If." the-presintered finally shaped body is still porous, it can be infiltrated with"a suitable-metal in-- stead: of:-bei-ng high sintered. For instance, it'- can be infiltr-atet. with 'silver which alloys with melybdehum and tungsten; whereby a vfully dense body of high rigidityand-strength is'obtainedv The infiltrant can also form a thi'n coating on the final shape and be used as an in termedi'ary :la'y-erlfo'r applying thereto a desired I corrosion resistant outer layer. If a=melt"of titanium is'--used as-.-infiltrant which-also alloys" with molybdenumrand tungsten to some extent, a thin'layer-formed-therefrom'on the final shape" canmb oxidized on its outside to form' the -desired dense and-corrosion resistant coating:

If ferrous metal"- powder is used for producing the-final shape in the manner .hereinbefo're. de-:L scribed,-" it ispreferred-to use pure iron powder of suitable fine particle" sizexto obtain'a "porous final shape-Which is: infiltrated thereafter :with a -sui-ta bl'e copper all'oyq It is advantageousitinir such cases to have carbon present in the ferrous? shape; up to -about: 0.25 :to 0.4% Whereasa such oarboircan be admixed-in finely divided solid state, such as; in: "the form :ofa lamp black, to the initial iron powderit*is::preierred to treat-:the 'preshapezof greatenporosity' than the final shape r witha gaseouscarbonzdischarging medium, such; asr carbon monoxidea by exposing the ,preshape to 'anvatmosphere of the at. a temperature aboRze- YZSWCE and preferably within :presintercarburized to the desired extentvstated and-"si mnltaneously';:presintered. It is alsopossible to carburizesa still porous final shape-in the mannery:deseriried. The copper alloy is. infiltrated w into theaoarburlzed vor carbon containing ferrous I final-shape. lnroases wherecarburizationof the shape. is effected'froni the gasphase or solid carbon: has wbeen; admixed with the initial; iron powder,- the proper shaping of -the edges. inzthefl Tfinalrshaping operation sometimes causes, di-ffi-.-

culties-and-xthe edges are therefore decarburized t0-:desired-:extent befere the finalshapingoper-a tion. TO'rthl'S effect,= thespreshape is covered with refractory .-material. .bu-tleavingv free i the edges :torbe-rdecarburized, and thelatter are ex-y I posed to a moisture containing atmosphere at about 1'l50 C. for a time period suifioient to effeet the desired degree of decarburization of the edges. In other cases, the final shape can be formed without endangering the edges but the sizing (coining) operation is apt to cause cracks in the edges; the latter can be decarburized to desired extent in the manner described before SlZll'lg.

The infiltration of a melt of a suitable metal in a porous final shape of molybdenum, tungsten or iron sometimes causes difiiculties in that the ends of the pores in surface layers have been closed in the final shaping operation; in such cases, the pore ends can be opened by dipping the final shape in a proper acid.

If a blade or bucket of ferrous material infiltrated with a copper alloy contains carbon, it can be heat treated. after infiltration in order to improve its physical properties, for instance it can be heated for one half hour at about 840 C., quenched in oil, redrawn for one half hour at about 680 C. and quenched again in oil and cooled in air.

Summarizing, the present invention is directed to a method for forming by powder metallurgy technique a fluid-guiding shaped body, such as a compressor blade of the type shown in Fig. 23, having generally curved longitudinally extending opposite side surfaces of substantial width and a longitudinal leading edge region and a longitudinal trailing edge region of smaller thickness than its center region, such as indicated by the cross-section of the cavity iii of the final shaping die shown in Fig. 22. In accordance with the invention, a metallic powder mass is first compacted into a porous compact of materially smaller width than the desired shaped body, the porous compact being formed with generally flat opposite edge surfaces such as indicated by the die cavity in Fig. 9, with the thickness of its leading edge region being greater than the thickness of the trailing edge, and the center region being greater than the two edge regions. The so produced shaped porous compact is thereafter sintered at an elevated sintering temperature for increasing its strength. The sintered compact is then subjected to a further shaping operation by forming pressure applied against its opposite wide side surfaces for laterally displacing the sintered powder mass of the trailing edge region of the compact and thereby forming it into a sintered porous body of a shape and width substantially corresponding to that of the desired fluid-guiding body.

The so further shaped sintered compact is thereafter infiltrated with an infiltrant metal of lower melting temperature than the metal of the compact for increasing the density and the strength of the sintered and further shaped body.

What I claim is:

1. In the method of forming a fluid-guiding shaped body, such as a compressor blade, having generally curved longitudinally extending opposite side surfaces of a certain width and at least one longitudinal edge having a thickness less than half the maximum thickness of its center region, the procedure comprising compacting a metallic powder mass into a porous compact of materially smaller width than said shaped body having generally flat opposite edge surfaces and with the thickness of at least one edge region of the compact being greater than the thickness of the corresponding longitudinal edge of said shaped body, sintering said porous compact at an elevated sintering temperature for increasing its strength, thereafter applying further forming pressure against the opposite side surfaces of said sintered compact for laterally displacing the sintered powder mass of said one edge region thereof for forming said compact into a sintered porous shaped body of a shape substantially corresponding to said fluid-guiding body of desired width and thereafter infiltrating the sintered shaped porous body with an infiltrant metal of lower melting temperature than the meta1 of said compact for increasing the density and strength of said body.

2. In the method of forming a fluid-guiding shaped body, such as a compressor blade, having generally curved longitudinally extending opposite side surfaces of a certain width and a longitudinal leading edge and a longitudinal trailing edge of smaller thickness than its center region with the trailing edge region being less than half the thickness of said center region, the procedure comprising compacting a metallic powder mass into a porous compact of materially smaller width than said shaped body having generally flat opposite edge surfaces and with the thickness of its longitudinal edge regions being greater than the thickness of the corresponding longitudinal edges of said shaped body, sintering said porous compact at an elevated sintering temperature for increasing its strength, thereafter applying further forming pressure against the opposite side surfaces of said sintered compact for laterally displacing the sintered powder mass of said trailing edge region thereof for forming said compact into a sintered porous shaped body of a shape substantially corresponding to said fluid-guiding body of desired width, and thereafter infiltrating the sintered shaped porous body with an infiltrant metal of lower melting temperature than the metal of said compact for increasing the density and strength of said body.

3. The method as claimed in claim 1, wherein .a longitudinal twist is imparted to the sintered body in the further forming operation.

4. The method as claimed in claim 2, wherein a longitudinal twist is imparted to the sintered body in the further forming operation.

RICHARD P. SEELIG.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,965,670 Schauer July 10, 1934 2,019,329 Warren Oct, 29, 1935 2,298,885 Hull Oct. 13, 1942 2,386,604 Goetzel Oct. 9, 1945 2,412,615 Howard Dec. 17, 1946 2,422,193 Hague June 17, 1947 2,425,053 Swinehart Aug. 5, 1947 2,431,660 Gaudenzi Nov. 25, 1947 2,435,511 Rice Feb. 3, 1948 2,449,257 Tucker Sept. 14, 1948 2,449,515 Seelig Sept. 14, 1948 2,456,779 Goetzel Dec. 21, 1948 2,520,373 Price Aug. 29, 1950 2,540,457 Rice Feb. 6, 1951 FOREIGN PATENTS Number Country Date 551,326 France Jan. 6, 1923 523,318 Great Britain July 11, 1940 

